clutch nightmare

Guest · Post by **Guest** » Sun Feb 01, 2004 8:23 pm

HI everyone,
I have a 75 vw bus that has a rebuilt non original engine in it. It is a pancake style, and was told that it was a 1800cc engine. The problem is that when I went to fix a leaky rear main seal, I discovered the clutch was a 210mm instead of a 215mm. My engine number starts with GD which would make the engine a 2000cc. Should I put a new 210mm on it? HELP

Post by **Marc** » Sun Feb 01, 2004 8:29 pm

The flywheel now on the engine determines whether it will use a 210, 215, or 228mm clutch assembly...if you want to use a different size clutch, you'll also need to change the flywheel (note that this involves checking the crankshaft endplay and reshimming it if needed).

Guest · Post by **Guest** » Sun Feb 01, 2004 8:40 pm

will it be fine to use a 210mm, eventhough that is what is on it now. I have heard the the wrong size clutch for your engine size can cause the rear main seal to tear. If this is true, that could possibly be the cause of hte leaky rear main, Right?

MASSIVE TYPE IV · Post by **MASSIVE TYPE IV** » Sun Feb 01, 2004 9:39 pm

the GD should be mated to an 091 gearbox in a 76-77 bus... it SHOULD have a 228mm flywheel.

Guest · Post by **Guest** » Sun Feb 01, 2004 10:17 pm

Thats what I thought. I guess my question now is why would a 210mm clutch be on the engine anyway? Could it be thet the engine casing doesnt match with the rebuilt engine, or is just that someone didn't know what they were doing and put on the wrong clutch. Forgive me intense questioning, but this is the first time I have worked on a vw.

MASSIVE TYPE IV · Post by **MASSIVE TYPE IV** » Sun Feb 01, 2004 10:28 pm

take pics of your flywheel and pressure plate email them to me...

Guest · Post by **Guest** » Sun Feb 01, 2004 10:33 pm

Wish I could Jake, but I don't have a digital camera. Hey, thanks for the offer.

raygreenwood · Post by **raygreenwood** » Mon Feb 02, 2004 10:45 am

One thinh to look very carefully for. In some of the last 411/412...and some of the later larger engines, there were some that used the vanagon rear seal dimension from the factory. I have two of them on EA cases. If you use the normal seal, it will press inalmost 2mm too far. This will leave the lips of the seal partially unloaded...causing high pressure leakage over 60 mph, especially in hot weather. Check the depth of the seal recess when you have the seal out, against the stock 10mm seal. If its deeper...you need the vanagon seal. Ray

Guest · Post by **Guest** » Mon Feb 02, 2004 11:48 am

thanks for the tip on the seal. Do you have any insight about what to do about the clutch?

dstar5000 · Post by **dstar5000** » Mon Feb 02, 2004 1:00 pm

Anonymous wrote:thanks for the tip on the seal. Do you have any insight about what to do about the clutch?

Welllllll, IF the guy *rebuilt* the engine with a 1800 crank and a 2000 FW, I would be scared that the eninge would fly *apart* after a few miles.....

DOn